GM Service Manual Online
For 1990-2009 cars only
Table 1: Input Shaft and Planetary Assembly Installation
Table 2: Rear Output Shaft Assembly
Table 3: Shift Fork Assemblies and Rear Output Shaft Assembly Installation
Table 4: Front Output Shaft Assembly, Drive Chain, and Oil Pump Suction Pipe Installation
Table 5: Transfer Case Rear Case Half Installation
Table 6: Rear Output Shaft Seal and Shift Detent Plunger Assembly Installation
Table 7: Access Hole Plugs, Fill and Drain Plug, Vent, 2/4 Wheel Drive Actuator, and Vehicle Speed Sensor Installation
Table 8: Input Shaft Seal and Front Output Shaft Seal Installation

Input Shaft and Planetary Assembly Installation


Object Number: 1846042  Size: MF

Input Shaft and Planetary Assembly Installation

Callout

Component Name

1

Transfer Case Input Shaft Bearing Assembly

2

Transfer Case Input Shaft Inner Retaining Ring

3

Transfer Case High/Low Planetary Carrier Assembly

4

Transfer Case Planetary Carrier Sun Gear Thrust Washer

5

Transfer Case Input Shaft

6

Transfer Case Planetary Carrier Sun Gear Thrust Washer

7

Transfer Case High/Low Locking Plate

8

Transfer Case High/Low Planetary Carrier Retaining Ring

9

Transfer Case Input Shaft/Planetary Assembly

10

Transfer Case Input Shaft Bearing Outer Retaining Ring

Rear Output Shaft Assembly


Object Number: 1846043  Size: MF

Rear Output Shaft Assembly

Callout

Component Name

1

Transfer Case Rear Output Shaft

2

Transfer Case Two/Four Wheel Drive Synchronizer Hub

3

Transfer Case Two/Four Wheel Drive Synchronizer Insert (Qty: 3)

Tip
Ensure that the inserts are installed in the correct orientation in the synchronizer hub. The inserts should be able to move when correctly installed.

4

Transfer Case Two/Four Wheel Drive Synchronizer Sleeve

5

Transfer Case Two/Four Wheel Drive Synchronizer Assembly

6

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring

7

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring

8

Transfer Case Front Output Shaft Drive Sprocket

9

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

10

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

11

Transfer Case Oil Pump Assembly

12

Transfer Case Rear Output Shaft Speed Reluctor Wheel

13

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

14

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip

    • Use an arbor press or suitable installer to install the bearing to the rear output shaft.
    • Ensure the retaining ring groove in the outer race is positioned toward the rear.

15

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

Shift Fork Assemblies and Rear Output Shaft Assembly Installation


Object Number: 1846044  Size: MF

Shift Fork Assemblies and Rear Output Shaft Assembly Installation

Callout

Component Name

Preliminary Procedure

    • Load all 4 components simultaneously.
    • The two/four wheel drive actuator cam profile will be aligned with the shift detent plunger bore when fully installed.

1

Transfer Case High/Low Clutch

2

Transfer Case Two/Four Wheel Drive Shift Fork Assembly

3

Transfer Case High/Low Shift Fork Assembly

4

Transfer Case Rear Output Shaft Assembly

Front Output Shaft Assembly, Drive Chain, and Oil Pump Suction Pipe Installation


Object Number: 1846045  Size: MF

Front Output Shaft Assembly, Drive Chain, and Oil Pump Suction Pipe Installation

Callout

Component Name

1

Transfer Case Front Output Shaft Assembly, Transfer Case Front Output Shaft Drive Chain Assembly

Tip

    • Install the chain with the darkened links facing up.
    • Install the front output shaft assembly into the front case half while engaging the chain with the drive sprocket.

2

Transfer Case Shift Fork Spring

3

Transfer Case Oil Pump Suction Pipe Seal

Tip

    • Use a NEW seal.
    • Lubricate the seal to ease installation.
    • Install the seal to the pipe prior to inserting the pipe into the pump.

4

Transfer Case Oil Pump Suction Pipe

Transfer Case Rear Case Half Installation


Object Number: 1846046  Size: MF

Transfer Case Rear Case Half Installation

Callout

Component Name

1

Transfer Case Two/Four Wheel Drive Actuator Seal

2

Sealer GM P/N 12345739 (Canadian P/N 10953541) or Equivalent

Notice: Apply the proper amount of sealant to the flange when assembling the transfer case. Excessive amounts of sealant can plug the oil pump screen, resulting in internal component failure.

Tip

    • Ensure both sealing surfaces of the front and rear case halves are free of dirt, oil, and cleaning solvent.
    • Apply a 2 mm (0.078 in) bead of sealant to the front case half.

3

Transfer Case Rear Case Half

Tip

    • Ensure the transfer case rear output shaft outer retaining ring is in place and aligned prior to mating case halves.
    • Use snap ring pliers to open the transfer case rear output shaft outer retaining ring for the transfer case rear output shaft rear bearing assembly.
    • Insert a rubber coated screwdriver into the speed sensor hole and lift up on the reluctor wheel to engage the retaining ring with the rear bearing assembly.

4

Transfer Case Bracket

5

Transfer Case Bolts (Qty: 17)

Notice: Refer to Fastener Notice in the Preface section.

Tip
Tighten the bolts by hand. Do not use an air gun.

Tighten
25 N·m (18 lb ft)

Rear Output Shaft Seal and Shift Detent Plunger Assembly Installation


Object Number: 1846047  Size: MF

Rear Output Shaft Seal and Shift Detent Plunger Assembly Installation

Callout

Component Name

1

Transfer Case Rear Output Shaft Seal (Heavy Duty and Super Heavy Duty)

Tip
Align the notch on the seal between the rear output bearing retaining ring access holes. This will position the weep hole down.

Special Tools

    • DT-48021 Seal Installer
    • J 8092 Driver Handle

2

Transfer Case Shift Detent Plunger

3

Transfer Case Shift Detent Spring

4

Transfer Case Shift Detent Plunger Plug Seal

Tip
Lightly lubricate the O-ring with clean DEXRON®VI.

5

Transfer Case Shift Detent Plunger Plug

Notice: Refer to Component Fastener Tightening Notice in the Preface section.

Tighten
20 N·m (15 lb ft)

Access Hole Plugs, Fill and Drain Plug, Vent, 2/4 Wheel Drive Actuator, and Vehicle Speed Sensor Installation


Object Number: 1846048  Size: MF

Access Hole Plugs, Fill and Drain Plug, Vent, 2/4 Wheel Drive Actuator, and Vehicle Speed Sensor Installation

Callout

Component Name

1

Transfer Case Two/Four Wheel Drive Actuator Assembly

2

Transfer Case Two/Four Wheel Drive Actuator Bolt/Screw

Notice: Refer to Fastener Notice in the Preface section.

Tighten
18 N·m (13 lb ft)

3

Transfer Case Oil Fill Plug

Tip
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil fill plug before installation.

Tighten
18 N·m (13 lb ft)

4

Transfer Case Oil Drain Plug

Tip
Apply pipe sealant GM P/N 12346004 (Canadian P/N 10953480) to the oil drain plug before installation.

Tighten
18 N·m (13 lb ft)

5

Transfer Case Vent

Tip
Apply retaining compound GM P/N 12377901 (Canadian P/N 10953504) to the vent pipe before installation, if removed during disassembly.

6

Vehicle Speed Sensor O-Ring Seal

Tip
Lightly lubricate the O-ring with clean DEXRON®VI.

7

Vehicle Speed Sensor Assembly

Tighten
17 N·m (13 lb ft)

8

Transfer Case Access Hole Plugs (Qty: 2)

Input Shaft Seal and Front Output Shaft Seal Installation


Object Number: 1846049  Size: MF

Input Shaft Seal and Front Output Shaft Seal Installation

Callout

Component Name

1

Transfer Case Input Shaft Seal

Tip
Ensure the bore of the front case half is free of dirt, oil, and cleaning solvent.

Special Tools

J 42738 Seal Installer

2

Transfer Case Front Output Shaft Seal

Special Tools

    • J 8092 Driver Handle
    • J 43484 Front Output Shaft Seal Installer

3

Transfer Case Assembly

Tip
Remove from the J 3289-20 and remove the J 45759 from the transfer case.